ES2256324T3 - MAGNETIC SUBSTRATES, COMOPOSITION AND PROCEDURE FOR MANUFACTURING. - Google Patents

Abstract

A process of making a magnetic assembly having at least one magnetic layer and at least one printable substrate layer including the steps of providing a magnetic composition comprising about 70 wt-% to about 95 wt-% of at least one magnetic material and about 5 wt-% to about 30 wt-% of at least one thermoplastic binder, forming the magnetic composition into a magnetic layer, and directly applying the magnetic composition at an elevated temperature in molten form to a printable substrate layer, and to the magnetic composition and any articles made therefrom.

Description

Magnetic substrates, composition and procedure for its manufacture.

The present invention relates to a method of manufacture of a magnetic set, printable, which self-adheres to an attracted surface magnetically, to a magnetic composition to make it, and articles made with it.

Permanent flexible magnetic materials they are frequently supplied in the form of sheets or rolls, and have been commercially available for many years. These materials are typically prepared by mixing a ferrite material powder with a suitable polymeric or plastic binder, in a uniform mix. Polymeric materials are often elastomers, and the process is therefore typically performed with the use of laminated or calendered extrusion. The mixture is converts in the form of a strip or sheet, which provides a permanent stable product that is usually somewhat flexible, and that It can be easily manipulated and transformed into elements of any desired configuration by cutting and / or stamping.

The magnetic material is magnetized so permanent, so that the resulting elements can act individually as permanent magnets, the magnetic field being of sufficient intensity for them to adhere to a magnetically attracted surface, such as the surface of a iron or steel sheet, even through a sheet of paper or thin cardboard. Many magnetic materials and materials resulting laminates, are typically of an inherently dark color, and therefore it is usual for these magnets to be attached to a printable substrate such as paper or plastic by gluing. It is therefore on paper or plastic where you can print the Design and / or other information. A usual application of such materials is that of thin, flat magnets, which have in their external surface some decorative design and / or some information promotional, including direct mail advertising, insertions in newspapers, and so on, upper parts of boxes, coupons, business cards, calendars, business cards Congratulations, postcards, and so on.

These magnetic pieces can be placed then on a magnetically attracted surface such as a refrigerator, filing cabinet, or other surface where they can be used as a reminder, and often used to hold sheets of paper such as notes, receipts, lists, Children's illustrations, reminders, etc.

In the usual manufacture of these products, Multiple producers are involved in the procedure. By For example, a printing press produces printed material in large impressions on continuous coils or on individual sheets. If it is in continuous coil shape, the continuous coil is cut into sheets individual and then sent to a magnet manufacturer where the magnetic material and the printed material join together with the use of a layer of adhesive. Alternatively, the printer you can acquire or otherwise obtain magnets and join then the material printed to the magnets with the use of a layer of adhesive, or you can send both pieces to a third party where the pieces are joined with the use of a layer of adhesive.

The Japan Patent Summary no. 01 131 262 describes a composition comprising from 5 to 20% by weight of polyolefin and 80 to 95% by weight of magnetic substance powder. The plastic magnetic composition is suitable as a generator of little size.

US 5,994,990 describes a procedure for selecting a printing sheet, molding by extrusion of a synthetic resin material that contains particles magnetic to form a sheet that has N and S poles formed in a surface by magnetizing multiple poles, and then bonding of a non-magnetized surface on the sheet of magnet and print sheet with each other, using a Acryl urethane type adhesive.

There is a need in the state of the art to simplify the production process of such parts magnetic

The technical problem of the invention consists in provide an improved production procedure for parts magnetic

This problem has been resolved by procedure according to claim 1.

Summary of the invention

The present invention relates to a unitary process of manufacturing a magnetic assembly, printable, in which at least one magnetic layer can be formed directly and attached to a printable layer without the use of No additional adhesive layer. The adhesion between the layer magnetic and the printable substrate is sufficient so that it is not Requires no additional adhesive. The procedure allows the formation of the magnetic layer and the union of the magnetic layer to a printable substrate during a simple procedure. The formation and the union is carried out at an elevated temperature, sufficient to provide the magnetic layer in plastic or flexible form.

The procedure may also include a stage of magnetization that can be carried out, either when the layer magnetic is at an elevated temperature, or when It has cooled to room temperature.

The magnetic layer comprises between about 70% by weight and about 95% by weight, of at least one magnetic material, and from about 5% by weight to about 30% by weight of at least one thermoplastic material.
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In an embodiment of the present invention, the magnetic material has the general formula M 2+ O6Fe 2 O 3 (MFe 12 O 19) where M is a metal divalent Advantageously, M is barium, strontium or lead. In some embodiments, the polymeric binder includes at least one amorphous polypropylene.

The procedure includes the application of the layer magnetic directly on the printable substrate at temperatures raised to which the magnetic layer is flexible and / or fit plastic. The procedure has the advantage that it is not required No additional adhesive layer.

Brief description of the drawings

Figure 1 is a side view, in section transverse, of the magnetic assembly of the present invention.

Figure 2 illustrates an embodiment of the present invention in which the magnetic layer is in a discrete position on a printable substrate layer.

Figure 3 illustrates an embodiment in which the magnetic layer is of a length and width substantially same as the printable substrate layer.

Figure 4a is a perspective view of the magnetic tag assembly of the present invention, shown About an article.

Figure 4b is an alternative embodiment to the shown in Figure 4a, in which the magnetic assembly has been also equipped with an overlaminate.

Figure 5 illustrates an embodiment of the assembly magnetic of the present invention in which they can be produced individual pieces from a laminated or continuous material.

Figure 6 illustrates an alternative embodiment as shown in Figure 5, in which the magnetic layer is located in discrete areas along the continuous coil or the printable substrate sheet.

Figure 7 is a perspective view of a embodiment of the present invention, in which a compilation of a plurality of magnetic sets individual.

Figure 8 illustrates an embodiment of the assembly magnetic of the present invention.

Figure 9 illustrates an alternative embodiment of the magnetic assembly of the present invention.

Figure 10 illustrates another alternative embodiment of the magnetic assembly of the present invention.

Figure 11 is a side view of a embodiment of the magnetic assembly of the present invention, which It also includes a releasable coating and an overlaminate.

Figure 12 is a plan view of the embodiment shown in Figure 11, in which the overlaminate It also includes perforations.

Figure 13 shows the embodiment described in Figures 11 and 12 in laminated form.

Figure 14 is a side view of a alternative embodiment of the magnetic assembly of the present invention.

Figure 15 is a plan view of the embodiment shown in Figure 14.

Detailed description of the preferred embodiments

The present invention relates to a method novel embodiment of a magnetic set, printable, and to a magnetic composition and articles made with it.

The magnetic substrate layer may include adequately from about 75% by weight to about 95% by weight, more adequately from about 80% by weight to around 92% by weight, and more adequately from around 85% by weight up to about 90% by weight of a material magnetic, suitably from about 5% by weight to around 25% by weight, more adequately from around 8% by weight up to about 20% by weight, and more adequately from about 10% by weight up to about 15% in weight, of a polymeric binder. The magnetic material is found uniformly dispersed in the polymeric binder.

As used here, the term "magnetic" (when applied to a substrate, an article, a object, etc.), will refer to any material that presents a permanent magnetic behavior or that is easily permanently magnetizable.

Magnetic materials that are particularly suitable for use herein, include ferrites that have the general formula (M 2+ O6Fe 2 O 3), where M represents Ba or Mr.

Other examples of suitable magnetic materials For use herein, include a magnet rare-cobalt-earth of RCO5, where R is one or more of the rare earth elements such as Sm or Pr, yttrium (Y), lanthanum (La), cerium (Ce), and so on.

Other specific examples of materials Magnetic include, for example, manganese-bismuth,  manganese-aluminum, etc.

The method of the present invention is not limited to any particular magnetic material, and therefore not It is intended that the scope of the invention be limited as such. While the materials described above find a particular use in the process herein invention, they may also find utility therein other materials that can be easily magnetized so permanent.

The magnetic composition properly includes approximately 70% by weight or more of the magnetic material so which has a force of attraction sufficient for uses practical. However, it is usually impractical to use more than 95% by weight of magnetic material because it affects the production, and also due to the difficulty of retaining more of this amount in the binding material. Also, include more than 95% in Magnetic material weight can lead to more surface rough. The magnetic material is often applied in the form of powder.

The magnetic intensity of the finished product is a function of the amount of magnetic material or powder of the mixture, surface area, thickness, and method of magnetization (for example, if it is aligned or not).

The thermoplastic material, known as frequency in the industry as a thermoplastic material, suitable For use in the process of the present invention, you can include any polymeric material that is easily processable with the magnetic material on, for example, the thermoplastic or the hot melt processing equipment as described with greater detail in what follows. Such thermoplastic materials include both thermoplastic elastomers and non-elastomers, or any mixture of same.

The thermoplastic composition can be chosen in based on at least the type of printable substrate that is being using, and the adhesion obtained between the thermoplastic composition and the printable substrate.

Examples of suitable thermoplastic elastomers for use herein include, but are not limited to, rubbers natural and synthetic and elastic block copolymers, such as butyl rubber, neoprene, copolymers of ethylene-propylene (EPM), polymers of ethylene-propylene-diene (EPDM), polyisobutylene, polybutadiene, polyisoprene, styrene-butadiene (SBR), styrene-butadiene-styrene (SBS), styrene-ethylene-butylene-styrene  (SEBS), styrene-isoprene-styrene (SIS), styrene-isoprene (SI), styrene-ethylene / propylene (SEP), elastomers polyester, polyurethane elastomers, to mention only a few few, and so on, and mixtures thereof. Whenever appropriate, within the scope of this invention are included any copolymers of the materials described in what precedes.

Examples of suitable thermoplastic elastomers commercially available such as SBS, SEBS, or SIS copolymers, include KRATONS® G block copolymers (SEBS or SEP) KRATON® D (SIS not SBS) available in Kraton Polymers; block copolymers VECTOR® (SIS or SBS) available from Dexco Chemical Co., and copolymers  FINAPRENE® block (SIS or SBS) available in Atofina.

Some examples of non-elastomeric polymers include, but are not limited to, polyolefins that include polyethylene, polypropylene, polybutylene and copolymers and terpolymers thereof, such as ethylene copolymers vinyl acetate (EVA), ethylene n-butyl acrylates (EnBA), methyl (meth) ethylene acrylates including acrylates of methyl ethylene (EMA), ethyl (meth) ethylene acrylates including ethyl ethylene acrylates (EEA), ethylene interpolymers with at least one C3 to C20 alphaolefin, polyamides, polyesters, polyurethanes, to mention only a few, and so on, and mixtures thereof. Where appropriate, the copolymers of the materials described above have Also useful here.

Examples of polymers useful herein can be found in US 6,262,174. Polymeric compositions that exhibit high hot tack have proved particularly suitable for use herein. Hot stickiness is a term known in the art to those skilled in the art.
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Examples of polymers commercially available non-elastomeric include EnBA copolymers available from companies such as Atofina Bajo the LOTRYL® brand (V, in Exxon Mobil under the ESCORENE® brand, in Du Pont de Nemours & Co. under the ELVALOY® brand, EMA copolymers available at Exxon Chemical Co. under the OPTEMAO® brand; EVA copolymers are available at Du Pont under the brand ELVAX® and Equistar under the ULTRATHENE® brand to name Only a few.

In some embodiments of the present invention, the binder includes at least one polyolefin or polyalphaolefin, or a copolymer or terpolymer thereof. Examples of useful polyolefins include, but are not limited to, amorphous polyolefins (i.e. atactic) (APAO) that include amorphous propylene homopolymers, propylene copolymers / ethylene, propylene / butylene copolymers and terpolymers of propylene / ethylene / butylene; isotactic polyalphaolefins; and linear or substantially linear interpolymers of ethylene and at minus an alpha olefin including, for example, ethylene and 1-octene, ethylene and 1-butene, ethylene and 1-hexene, ethylene and 1-pentene, ethylene and 1-heptene, and ethylene and 4-methyl-1-pentene, and so on. In some embodiments, it may be preferable. employ a small amount of another polymer in combination with the polyalphaolefin, such as anhydride grafted polymers maleic, which have been used to improve wetting and accession. Another chemical graft can be used, but the anhydride Maleic is by far the most common. Normally, they are used only small percentages in the graft (1-5%), and for the most part they tend to be copolymers of ethylene or propylene.

The terms "polyolefin" and "polyalphaolefin" are frequently used in a way interchangeable, and in fact, they are frequently used in a way interchangeable to describe amorphous polypropylenes (homo-, co- and ter-polymers). For a detailed description of such materials, see US 5,482,982, US-5,478,891 and US 5,397,843, US 4,857,594.

The term "alpha" is used to indicate the position of the atom or substitution group in a compound organic.

As used here, the terms "copolymer" and "interpolymer" will be used to refer to polymers that have two or more different comonomers, for example copolymer, terpolymer, and so on.

Examples of commercially amorphous polyolefins available, suitable for use herein, include the available under the REXTACS brand at Huntsman Polymners, including polypropylene homopolymers, copolymers of propylene / ethylene and propylene-butene copolymers; VESTOPLASTt APAOs available in Hills that include homopolymers and copolymers, as well as the terpolymers of propylene / ethylene / butene; as well as those available in Rexene and those available under the EASTOFLEX® brand available at Eastman Chemical Co of Kingsport, TN.

Examples of copolymers of a polyolefin and of at least one alpha olefin, include catalyzed polyolefins of metallocene (interpolymers of ethylene and at least one alphaolefin) commercially available in Exxon under the EXXACT® brand, and in Dupont Dow Elastomers under the ENGAGE® brand, and in Dow under the brand AFFINITY®.

In a particular embodiment, the binder is a amorphous polyalphaolefin available at Eastman Chemical Co., under the EASTOFLEX® brand. It has been found that amorphous polyalphaolefins when used in combination with the magnetic material, provide excellent adhesion to the printable substrate without Need for another formulation. However, some materials Polymers may require the addition of bonding resins, plasticizers, etc., to provide adequate adhesion. The addition of low molecular weight plasticizers and / or resins of gluing, it can also improve the processability of the composition, as well as change the rheological properties and / or lower the melt viscosity of the composition.

Any of the useful polymeric materials Here, it can be used in combination with any other. In addition, other polymeric materials not described specifically here, they also find utility in the present invention The list described above, has been intended for illustrative purposes only, and is not intended that is limiting the scope of the present invention. An expert in the matter you can understand that there is a large number polymeric materials available that may have utility in the Present.

Bonding resins are available in numerous sources, including many of the companies mentioned above, and include, for example, resins of Hydrocarbon bonding such as those available at Eastman Chemical Co. under the EASTOTAC® brand; hydrocarbon resins of ESCOREZ® oil available in Exxon Mobil; resins of PICCOTAC® and PICCOLYTE® polyterpenes available in Hercules; resins  FORAL® hydrogenated and rosin ester resins, available in Hercules; WINGTAC® petroleum hydrocarbon resins available in Goodyear; REGALREZ® hydrocarbon resins and aromatic resins REGALITE® hydrogenates available at Hercules Inc; and so successively.

The plasticizers are available in Many sources and include plasticization oils, for example. Plasticization oils are often petroleum based and are They are available in several oil companies.

Waxes can also be optionally added to Compositions to lower melt viscosity and / or change the rheological characteristics

Other optional ingredients include although without limitation, antioxidants, dyes or pigments, UV agents, and so on. Such optional ingredients are known for those skilled in the art, and are typically added in casualties concentrations that do not adversely affect the characteristics Physical composition.

The list of materials described in what above, has been provided for illustrative purposes only, and in no way is exclusive of the materials that can be used in the magnetic composition of the present, and as such it is not intended to limit the scope of the present invention.

The amount of adhesion required between the printable substrate and magnetic composition will vary depending of the application, and of the printable substrate used. May it is desirable that the magnetic compositions have adhesion enough to extract the fiber from the printable substrate if it It is, for example, paper. The lack of fiber transfer can not always be indicative of poor adherence, however. By For example, a lack of delamination may also be adequate. For other types of substrates such as tissue substrates, of plastic or metallic, it may be desirable that the magnetic layer and the printable substrate layer does not separate easily, or does not delaminate

The bond strength between the magnetic layer and the printable substrate can be checked using debarked at 180º or 90º, for example, as known in the technique. Such methods can be found under the methods of ASTM test. The amount of force required to bark the Substrates will vary depending on the end use and the substrate printable. For some applications, a debarking force from about 78.75 to 157.48 g / cm (200 to 400 g / inch) it turns out adequate, and from 157.48 to 177.17 g / cm (400 to 450 g / inch) it constitutes an upper limit, while for some, the debarking resistances must exceed 393.70 to 590.55 g / cm (1000 to 1500 g / inch) or more. For example, for compositions thermoset polymeric, the debarking resistances are of up to 393.70 or 590.55 g / cm (1000 or 1500 g / inch) or more high.

It is desirable that the magnetic composition resulting has very little or no surface tack to room temperature. The binder and the mixture are very sensitive to degree of shear that presents Bingham plastic creep. In hot melt applications, the viscosity can be as low as 4000 cps at around 150ºC (300ºF) or as high as 200,000 cps at around 150ºC (300ºF). Since the temperature It is a significant factor, it is not uncommon for the coating Extrusion is done at temperatures as high as melting temperatures from about 315 ° C to about 345 ° C (around 600ºF to around 650ºF).

The temperature at which the magnetic composition is applied to the substrate may be completely different from the temperature present inside the extruder. The magnetic composition after its exit from the extruder and the application head, and thus after the formation, that is to say conformation, of the magnetic layer, may have cooled to a substantial degree at the time of the application of the magnetic layer now. formed, to the printable substrate layer. However, the magnetic composition must remain at an elevated temperature, high enough to achieve a suitable bond between the magnetic layer and the printed substrate layer.
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Magnetic material and thermoplastic binder and / or the other ingredients, mix at elevated temperatures using standard thermoplastic mixing equipment, such as extruders, mixers Baker Perkins, Banbury, extruders single or double spindle, Farrel Continuous mixers, and equipment High shear mix.

The mixture can be composed of, and be shaped in a manner such as in, flakes, balls, or in any form known in the art, which is suitable for a feed storage for extrusion or any other fusion processing equipment, which is then supplied to The coating company. The coating company can then use a high pressure single screw extruder, or other processing equipment to melt and pressurize the mixture, to force it through an application head such as a slot mold, a rotating screen head, or other head for such application, in the coating station. In this way, The extruder or other hot melt equipment supplies the resulting magnetic composition directly to the head of application. During extrusion or other fusion processing of The magnetic composition, the temperature can be sufficiently high so that the composition can be considered as molten, that is, in molten or liquid form.

In an alternative embodiment of the present invention, various ingredients can be supplied to the extruder in individual balls, flakes, and the like. By For example, if more than one thermoplastic binder is used, these are not they have to be supplied as a mixture already in balls or in leaflets. Each of them can be supplied individually in the form of balls or flakes, for example.

Coating companies can use a variety of application procedures known in the technique. Examples of application procedures useful for application of the magnetic composition to the printable substrate include, but are not limited to, slot mold coating, roller coating or reverse roller coating, blade-roller printing e inverted direct printing, wire rod coating, air knife coating, hole coating low cut, screen printing with hot screen, etc.

In an embodiment of the present invention, the Slot mold recording is used in combination with a single screw extruder.

In another embodiment of the present invention, employs a method known in the industry as "flex-o-press" ("flexocompression"). The term "flex-o-press" as used herein, it refers generally to a coating method of four rollers whereby a first roller is provided with head, and typically rotates at a speed that is half of the second roller The second roller carries the thermoplastic mixture / magnetic The third roller is a roller plate roller that it is a "flexocompressor" silicone roller, and it can have a surface modeled with elevated areas for the application of the magnetic composition of the present invention to the substrate Printable according to a predetermined pattern. This roller enters slight contact with the second roller and then transfers the thermoplastic / magnetic mixture to a fourth roller. See roll R.T. Coating Schorenberg, Modern Plastic Encyclopedia, 1984-1985, pp. 202-203. Other Useful reference is Coatings Technology Handbook, 2nd Edition, Satas and Tracton, Marcel Dekker, Inc., 2001. Desirably, the team of processing includes a cold roller to increase speed to which the resulting magnetic composition cools and stabilizes, which includes at least the magnetic material and a binder thermoplastic This is advantageous for faster processing. the resulting composition in rolls or sheets, for example.

Line speeds may vary by any case up to 152.4 m (500 ft) per minute, or be more high.

The above methods allowed, by otherwise, linear speeds of only about 12.2 - 24.4 m (40 - 80 feet) per minute.

The present invention thus allows speeds of line that are much faster than those of the methods used habitually. Line speed may be limited by the capacity of the extruder or other application equipment used in the present method, as well as by the type and size of the mold, nozzle, or other application head used, of the pressure used, of the viscosity of the magnetic composition, and of the application temperature, as experts in the matter.

Any method that allows the application Direct magnetic, thermoplastic, temperature composition elevated when it is in flexible form or in plastic form, when printable substrate, may be used herein. Using the method of the present invention, the magnetic composition thermoplastic adheres directly to the desired substrate in any desired shape or configuration, without the need for any additional adhesive layer. That way, the magnetic layer resulting is formed and attached to the printable substrate layer in A single or unitary procedure.

The above methods, on the contrary, require the formation of the magnetic layer, the cutting of the layer magnetic, and then linking the magnetic layer to substrate by using an additional adhesive layer to form the magnetic set that is done well using multiple procedures The magnetic layer is supplied, either in the form of roll, either pre-cut with your settings desired as required for the purposes for which the layer magnetic has to serve, and is linked to the substrate layer printable. The present invention, by contrast, allows formation of the complete magnetic assembly in a single procedure. Thus, the present invention provides a further method. effective against the above methods.

Using the method of the present invention, the mixture of binder and magnetic material is applied to a substrate printable at an elevated temperature at which the binder Thermoplastic is in flexible or plastic form. The present invention forms the magnetic composition according to its configuration finish at a temperature sufficient to provide a wet and a suitable adhesion between the magnetic composition and the printable substrate. Of course, membership will also depend on the composition of the binder that has been selected. Some binders will provide better adhesion than others.

The substrate to which the composition can be attached magnetic using the method of the present invention, it may be any suitable printable substrate, including, by example, paper and paper products, cardboard, plastic materials and polymeric, metal, releasable coatings such as a releasable silicone, textile or fabric lining, and so on successively. You can also use combinations of any of the substrates. In some embodiments, it can be use a releasable coating in combination with another printable substrate, one on each side of the magnetic layer, by example. The magnetic assembly that includes the printable substrate And the magnetic layer, can be removed after coating releasable at the place of use.

The required application temperature can depend on numerous factors, including melting temperature of the thermoplastic binder, the viscosity of the magnetic composition resulting, and so on. The melting temperature and the viscosity may vary depending not only on the type of binder used, but of the other ingredients that can be used in the magnetic composition as described above. The higher the viscosity or melting temperature, the more high is the temperature that may be required to apply with Successful magnetic composition. This also depends, of course, of the application equipment used. In general, the materials Thermoplastics are applied at temperatures of around 135 ° C at around 190ºC (around 275ºF to around 375ºF), although Some can be applied at higher or lower temperatures. For example, thermoplastics of very low viscosity can be applied at temperatures as low as around 90 ° C (around 190ºF). Some can be applied at temperatures as high as around 205ºC (around 400ºF), or more high, for example polyamide materials are applied with frequency at temperatures around 205ºC (around 400ºF). The temperatures used may however exceed even 318ºC (650ºF). However, more temperatures elevated thermoplastic materials lead to rapid material degradation A range of application temperature frequently used, it is around 160ºC around from 190ºC (around 325ºF to around 375ºF), being very common that of around 175ºC (around 350ºF). In an embodiment of The present invention, polypropylene is used, and can be applied at temperatures above 205ºC (400ºF). Even more, using extrusion techniques, polyethylene is extruded commonly above 306ºC (600ºF) at high speeds.

The temperature should be enough to lower the viscosity of the thermoplastic material to allow thermoplastic material adheres sufficiently to the substrate printable. This may include penetration into, or the "wet" of the surface of the substrate to which it is applying The thermoplastic material must be sufficiently adhered to the substrate so that the delamination of the substrates

Using the method of the present invention, the resulting magnetic composition can be advantageously applied in a thin layer of about 50 µ to about 765 µ (about 0.002 inches to about 0.030 inches), suitably around 50 µ to about 510 µ (about 0.002 inches to about 0.020 inches), and more suitably around 50 µ to about 305 µ (about 0.002 inches to about 0.012 inches) of thickness. The present invention allows the application of a layer thinner binder / magnetic mixture. Extrusion methods and pre-calendering, on the contrary, did not allow layers magnetic from less than about 0.10 mm to about 0.20 mm (about 4 thousandths of an inch to about 8 thousandths of inch), and more frequently, 0.25 mm (10 thousandths of inch).

In an embodiment of the present invention, a Magnetic composition tape is applied at a temperature raised, in plastic state, to a printable substrate. Tape it can be applied to the substrate so that it is dimensionally coextensive with the printable substrate, that is, the same length and width, or it can be applied to the substrate in areas Discreet, preselected, only. In addition, they can be applied several tapes to the substrate simultaneously, and can be applied intermittently according to a discontinuous model. The line of application can be equipped in such a way that pressure is applied to the tape (s), to press the tape (s) ribbon (s) on the printable substrate. For example, you can Use a cold roller for this purpose.

The surface of the tape can also be contacted by a magnetization roller that smoothes, cools and magnetizes the tape (s). When this is done while the tape is still in a fluid state, an effect is provided Increased magnetic known as alignment. Tape can be applied with a thickness of between about 50 µ and around 510 µ (around 0.002 inches and around 0.020 inch)

In broad terms, the method of this invention allows the magnetic composition to be formed and applied directly to the printable substrate in a procedure Simple, unitary. The width, thickness and length of the layer Magnetic can be individually designed in any size desired, and may be designed to cover the entire substrate printable that is therefore applied dimensionally coextensive in general with the printable substrate, or it can be applied so that it covers some discrete portion of the substrate. In addition, it can be applied in a tight way by use of rubberized rubber roller, as described above (for example, flexocompressed).

In addition, the magnetic composition can be formed and fixed to the printable substrate in finished form, of substantially simultaneously. The thickness and width, or the thickness, width and length, can be according to its fixed shape final. As used herein, the term "so substantially simultaneous "may be used to indicate that It is happening during a simple manufacturing procedure.

The magnetic composition can be totally magnetized during the manufacturing process by supply of a magnetic field on the line, to the total width of the continuous coil after application of the composition magnetic to the printable substrate. The magnetization stage can be optionally included after printing, or after training of the article according to its desirable size and shape by cutting, stamping or punching as described below.

Additionally, the magnetization stage can be carried out while the thermoplastic binder is at High temperature. This results in an alignment of the magnetic particles with a significant increase in magnetic intensity of the article compared to it item magnetized at room temperature. See Sawa 4022701 e Ito 6190513.

Optionally, marks can be applied, it is say, printed contents, to the printable substrate with prior to joining with the magnetic layer, or they can be printed after it has been attached to the magnetic layer. For ease of production, printing may be desirable after that the magnetic material has been attached to the printable substrate. However, it is not necessary to apply any printing to the substrate printable. For example, in case of a notebook, you cannot Apply any impression. This allows the end user apply your own notes and reminders to sheets of paper individual.

Once the printed content has been applied to the printable substrate, varnishes, films can be provided or other protective surfaces that also improve the appearance of the substrate now printed, on the surface of the printed substrate. These materials, or similar ones, can be applied to the bare surface of the magnetized layer to avoid unexpected hitting or "blocking" of the combined item itself same, or other substrates if necessary.

Once the magnetic assembly has been manufactured entirely in the form of a roll or sheet, the configurations desired can be cut, perforated, stamped, or similar, to starting from the assembly, either at the point of manufacture of the material magnetic, or by those who are supplied the magnetic assembly, as desired. Laser cutting is a example of a method by which various forms can be formed items from the continuous sheet or coil.

Figure 1 generally illustrates with 10 a magnetic assembly as manufactured with the use of the present invention The magnetic layer 12 has been bonded to a layer 14 of printable substrate without the use of any adhesive layer additional.

Figure 2 generally illustrates with 10 a embodiment of the present invention in which the magnetic layer 14 it is applied in a discrete area of the printable substrate 12.

Figure 3 generally shows with 10 a alternative embodiment of the assembly of the present invention, in which the magnetic layer 14 has been shown so substantially coextensive with printable substrate layer 12, both in length 16 and width 18.

In a particular embodiment of the present invention, the magnetic set is a tag set magnetic The magnetic tag set is a set of magnetic label that includes magnetic layer 14 and layer 12 of printable substrate that has the desirable information or brands printed on it.

Figure 4a generally illustrates with 10, a magnetic tag assembly of the present invention, with the printable substrate layer 12 bonded to a magnetic layer 14. The magnetic layer is also subject to a releasable coating 26. The releasable coatings include those substrates that They include silicones, among others. This can be done. using means known in the state of the art, such as with  the use of a releasable pressure sensitive adhesive, such as a releasable hot melt adhesive, or a releasable adhesive dry, although in some embodiments, it may not be required no adhesive In addition, the complete set of layer 12 of printable substrate, magnetic layer 14 and coating releasable 26, may also be attached to an article such as a packaging, a cup, a book, a magazine or other article similar 22, with the use of a pressure sensitive adhesive or dry releasable (not shown). The magnetic assembly 10 can then be used in commerce, for advertising purposes or Promotional

In a particular embodiment, the set Magnetic is a magnetic tag set. The set of magnetic label is released releasably by any adhesive known to those skilled in the art, including water based adhesives and hot melt adhesives as well as well as other types, to the base article. Suitably the Adhesive is a pressure sensitive adhesive, and even more suitably, a pressure sensitive releasable adhesive, although the pressure sensitive adhesives used can also be permanent or semi-permanent type. The releasable coatings are, by virtue of their nature, difficult to adhere, so that the type of adhesive is not limited. Therefore, depending on the releasable coating used, adhesives can also be used semi-permanent and permanent, as well as a adhesive that is not pressure sensitive. The selection of adhesives It is known by experts in the field. However, in In any case, it is desirable that the adhesive forms a further bond  strong with the base article, which with the releasable coating, to allow easy separation of the magnetic assembly from to the base article. Once the magnetic set has separated, can then be placed on a surface magnetic such as a refrigerator, a closet, a bulletin board  or a magnetic signpost, and so on, for the purpose to show the marks printed on it.

An example of adhesive suitable for use in the present, includes a copolymer latex of ethylene vinyl acetate, and even more specifically, an aqueous dispersion containing 60% of solids by weight, which includes 22.4% by weight of ethylene and 77.6% by weight of vinyl acetate. The adhesive may include optionally a cross bond forming agent and / or a inorganic peroxide among other known optional ingredients by experts in the field.

The base article can be formed from any desired material and can have any structure to the that the label assembly can be released adherently magnetic In the previous example, the adhesive is therefore between the releasable liner and the base article.

Figure 4b shows an alternative embodiment. wherein the printable substrate layer 12 also has a overlaminate 30 extending over substrate layer 12 printable, which is substantially sized equivalent, at least length and width, to the magnetic layer (not represented). The overlaminate is preferably a material of transparent polymeric film. In this embodiment, I don't know requires no adhesive between the magnetic layer and the coating releasable, or releasable liner and article 22. The overlaminate has perforations that are dimensionally substantially equivalent in length and width to layer 12 of printable substrate and magnetic layer (not shown), for an easy separation of the magnetic assembly that includes the layer of Printable substrate and magnetic layer. Can be used Any number of perforations. Desirably, they are desirable to minus two perforations on opposite sides. Realizations like these are best discussed in relation to the Figures 11-13, described in detail in the following.

Optionally, the overlaminate can have substantially the same length, but a slightly more width large, or alternatively, substantially the same width, but a different length All sides of the overlaminate, or two opposite sides of the overlaminate, can be secured to a basic article with the use of an adhesive, for example. He Adhesive can be applied by strips, dots, or other patterns known to those skilled in the art. The adhesive can be separable, permanent or semi-permanent, as well as pressure sensitive or not pressure sensitive. Suitably the Adhesive is a permanent adhesive. The type of adhesive selected, however, is strictly a preference of the Username. The main consideration is that the whole magnetic be separable from overlaminate, as well as from basic article. This can be done, for example, with the use of perforations, so that a part of the overlaminate remains with the basic article, and another part remains with the whole magnetic. If perforations are used, it may be desirable to place the perforations just inside the adhesive.

The magnetic assembly can be released at continuation of the basic article breaking the perforations. In the particular embodiment described above, in which employs an overlaminate, the magnetic assembly can be adhered releasably to the releasable coating by using a adhesive, but no adhesive is required because the Overlaminate secures the magnetic assembly to the base article. Once released, the magnetic assembly can be self-adhering to a magnetic surface, such as a refrigerator, a closet, a notice board or notices magnetic, etc.

An optional embodiment may provide the magnetic set 10 packaged in a thin film by example, such as a polyolefin or copolymer based film of polyolefin, saran, mylar, or some such movie. A similar application to this, it is known in the industry of Binding or pressure sensitive adhesive industry as a magazine trim, in which ads or samples are Temporarily adhere to a magazine or book. Once it has separate from the packaging, book, magazine or similar, the whole magnetic 10 can be self-adhered to a magnetic surface such as a refrigerator or filing cabinet, for example.

Figure 5 generally illustrates with an assembly Magnetic of the present invention prior to formation of individual parts from the continuous sheet or coil, in which the magnetic layer 14 has been shown so substantially coextensive, in length 16 and width 18, with the printable substrate layer 12. In this embodiment, pieces individual such as tags, business cards, and the like, for example, they have been printed on the substrate layer 12 printable (the print has not been represented), in the form of sheet. The individual magnetic pieces 24 can be subsequently cut, stamped, perforated, etc., in the sheet, forming the perforations 26 the magnetic pieces 24 individual.

Figure 6 illustrates an alternative embodiment of that shown in Figure 5, in which the magnetic layer 14 has been applied in strips and pressed into discrete areas only over printable substrate layer 12. In this embodiment, it shows a magnetic layer 14 whose upper part will be cut each individual piece 24 when cut by perforations 26.

Optionally, the individual pieces can be linked to each other with a procedure similar to what is known in the industry as a "perfect" union. Using this procedure, individual parts or substrate sheets printable that have the magnetic layer, are stacked in a block or are They have a taco, fastened with a clamp to form a block, and then linked to each other with the use of an adhesive. The adhesive is applied to one side of the stack or taco, which can also be mentioned as the "loin" of block. A lid can be attached to the spine to prevent the adhesive adheres, in case it is an adhesive sensitive to the Pressure. If an adhesive that is not pressure sensitive is used, and that is not sticky, then no cover is needed. He Adhesive can be applied by roller spray or with any other means known in the art. An alternative to The use of an adhesive consists of stacking the magnetic pieces individual in a stack, block or block, and then wrap jointly contracted. Figure 7 illustrates in general with 20, a stack or block of individual magnetic assemblies 10. The Figures 8, 9 and 10 illustrate several embodiments in which the layer magnetic 14 is applied to the printable substrate 12, which in this Realization is a blank paper. Of course, paper can be personalized, or have messages printed on it, etc.

Figure 11 generally illustrates with 50, a view in cross section of an alternative embodiment of the assembly magnetic produced in accordance with the present invention. The layer magnetic 14 binds to printable substrate layer 12 without use No additional adhesive layer. A coating is used releasable 26 in combination with, and adjacent to, the magnetic layer 14. In this example, an overlaminate 28 is used to hold the set together. The overlaminate 28 has perforations 30 that can be used to separate the magnetic assembly 10 that includes printable substrate layer 12 and magnetic layer 14, of the releasable coating 26. In this case, no adhesive to fasten the release coating 26 to the layer magnetic 14. Figure 12 illustrates a plan view showing the perforations 30 formed in the overlaminate 28. These can be produced in sheet form, for example, as shown in general with 60 in Figure 13.

In a particular embodiment, the set magnetic as described above, is a set of magnetic tag

The assembly as shown in the Figures 11-13, is a four layer structure like the shown in cross section in Figure 11. They have not been used adhesives in this embodiment. The complete set includes a releasable coating 26, a magnetic layer 14, a layer 12 of printable substrate, and a transparent overlaminate 28.

Figure 14 illustrates an alternative embodiment in which the magnetic layer 14 is applied in discrete pieces 15 individually sized. This set is a construction of two layers, which has only printable substrate layer 12 and the magnetic layer 14. The printable substrate layer 12 has perforations 30 that match each discrete magnetic piece 15 individual, and that allow each magnetic set 10 of the present invention including layer 12 of printable substrate and magnetic layer 14, be easily separated from the sheet 60. The magnetic pieces 15 are adhered directly to printable substrate layer 12. Figure 15 illustrates a plan view of the embodiment of the sheet magnet described in Figure 14, showing perforations 30 in the printable substrate layer 12 matching the part individual magnetic 15 in order to provide a release easy.

The figures described above illustrate only some of the embodiments of the present invention, and they are provided as examples only, and do not limit the scope of the present invention to those embodiments as described here.

The method of the present invention, in which the magnetic composition is applied directly to the substrate Printable, allows all other stages to be also included in the unit manufacturing procedure of the present invention Optionally, any combination of stages printing, coating and shaping of the article by cutting, stamping, punching, and the like, may be included in The unit procedure.

Items that can be produced from this way, including, but not limited to, promotional pieces, greeting cards, postcards, advertisements commercial, magnetic business cards, business cards Reminder for interviews, announcements, propaganda, coupons, labels, calendars, catalogs, tourist attractions, frames of pictures, other informative purposes, and the like, that have a magnetic surface attached to a printable surface that can be self-adhered or self-bonded to A metal surface for exposure.

Ad cards may include, by example, children's ads, gift parties, weddings, anniversaries, meetings, announcements of "we have moved", and so on.

Promotional products include, by example, restaurant advertising, self-services, clinics veterinarians, real estate agents, maintenance services grass, insurance agents, etc., etc. These pieces Promotional can conveniently include phone numbers and addresses. In addition, adding calendars to such pieces, can improve the possibilities of use in refrigerators, by example.

Other examples include catalogs such as catalogs for sporting events, school events, and the like. Such articles have been provided as an example only, and not They are intended to limit the scope of the present invention. exist numerous uses for the magnetic assembly of the present invention, and a material expert will know how to use the set magnetic or modifications thereof, for other items that They have not been described here.

The items described above may be distributed through direct mailings by adding to magazines or newspapers, or the like.

Alternatively, the magnetic set of the The present invention can be used in children's toys such like paper dolls or character illustrations, or for example, in letters or numbers of self-adhesion to boards magnetic ads

It is intended that the above description be Illustrative and not exhaustive. The description may suggest many variations and alternatives to an expert in this field. The intention is to that all these alternatives and variations are included within of the scope of the claims in which the term "which comprises "means" that includes, but is not limited to ". Those who are familiar with this matter will recognize others. equivalences with the specific embodiments described herein, whose equivalents are expected to be covered by claims.

In addition, the particular characteristics that present dependent claims, can be combined with each other in other ways within the scope of the invention, such that the invention must be recognized as directed also specifically to other embodiments that have another possible combination of the features of the claims Dependents For example, for the purpose of publishing claims, any dependent claims that follow should be taken as an alternative drafted in multi-dependent of all claims above, which has all the background referenced in such dependent claim if such format multi-dependent is an accepted format within its jurisdictional scope (for example, each claim that depend directly on claim 1, it must be a alternative taken as dependent on all claims previous). In jurisdictions where the multi-dependent claim formats, the Following dependent claims shall be taken, each one of them, as written alternately in each format simply dependent that creates a dependency on the claim that the previous antecedent possesses, different from the specific claim related to said claim next dependent. For example, claim 3 may be alternatively taken as a dependent of claim 2, as well as also of claim 1; claim 4 may be taken alternatively as a dependent of any of the claims 2-3; claim 5 may be taken as alternately dependent on any of the claims 1-3; claim 6 may be taken alternatively as a dependent of any of the claims 1-4, etc.

The non-limiting examples that follow are more illustrative of the present invention.

Examples Example 1

Amorphous polypropylene P # 1023 supplied by Eastman Chemical Co., was mixed with HM410 ferrite powder Starbond supplied by Hoosier Magnetics, in quantities of 85% by weight of polypropylene and 15% by weight of the ferrite powder. The resulting mixture was processed at a temperature between 165ºC and around 190ºC (around 325ºF and around 375ºF), and was formed into belts using an extruder / a slot mold head, on a printable paper substrate. The thickness of the mixture was varied between about 0.0762 cm (0.003 inches) and 0.0305 cm (0.012 inches) (m to m).

This test was developed at variable speeds between 76.25 and 152.50 meters per minute (250 and 500 feet per minute), to cover discrete tapes, and around 24.40 meters per minute (80 feet per minute) for full coverage.

Claims (36)

1. A procedure of forming a set magnetic that has at least one magnetic layer that has dimensions of thickness, width and length, and at least one layer of printable substrate that has dimensions of thickness, width and Length, which includes the stages of: a) provide a magnetic composition of hot melt at an elevated temperature, said comprising magnetic hot melt a concentration of 70% by weight at 95% by weight of at least one magnetic material, and approximately from 5% by weight to approximately 30% by weight of at least one thermoplastic binder, and b) apply said composition directly hot melt magnetic at elevated temperature, when it is flexible, to a printable substrate layer. 2. The method of claim 1, which further comprises subjecting said magnetic assembly to a field strong magnetic enough to result in an effect permanent magnetic in the set, whether when the composition magnetic is at elevated temperature or when the composition Magnetic has cooled to room temperature. 3. The method of claim 1 or the claim 2, wherein said at least one magnetic material is present in an effective concentration to make said magnetic assembly be self-adherent to a substrate comprising a ferromagnetic material. 4. The procedure of any of the claims 1 to 3, wherein said fixed application stage b) said magnetic layer to said printable substrate layer in dimensions of thickness and width in its final form, or fixed said magnetic layer to said printable substrate layer in dimensions of thickness, width and length in its final form. 5. An article formation procedure in a block, comprising forming a plurality of sets magnetic laminates by the procedure of any of the claims 1 to 4, and layered together the laminated assemblies to form a stacked block. 6. The method of claim 5, in the that said plurality are joined together with an adhesive, or wrapped in contracted form. 7. The procedure of any of the claims 1 to 5, wherein said application temperature It goes from around 90ºC to around 205ºC. 8. The method of claim 1, in the that said training stage includes a stage chosen from extrusion, roller coating, printing coating, screen printing, and slot mold coating. 9. The procedure of any of the claims 1 to 8, wherein said magnetic material has the following general formula: M 2+ O6Fe 2 O 3 in which M represents a metal divalent 10. The method of claim 9, in which said divalent metal is barium, strontium, lead or a mixture thereof. 11. The procedure of any of the claims 1 to 10, wherein said at least one binder thermoplastic comprises at least one component selected in the group consisting of natural rubbers, block copolymers, polyolefins, polyalphaolefins, polyesters, polyamides, nails, polyurethanes, copolymers thereof, and mixtures thereof same. 12. The process of claims 1 to 11, wherein said at least one thermoplastic binder comprises the less an amorphous polypropylene, at least one ethylene interpolymer and at least one alphaolefin, at least one copolymer of ethylene and vinyl acetate, at least one copolymer of ethylene and (meth) acrylate, at least one copolymer of ethylene and n-butyl acrylate, and mixtures thereof. 13. The procedure of any of the claims 1 to 12, wherein said at least one binder thermoplastic comprises a mixture of acetate copolymers of Vinylethylene 14. The procedure of any of the claims 1 to 13, wherein said at least one layer magnetic has a thickness of about 50 µ to around 765 µ. 15. The procedure of any of the claims 1 to 14, wherein said magnetic composition is applies to said printable substrate in the form of at least one headband. 16. The method of claim 1, in which said magnetic layer is also attached to a coating releasable 17. The method of claim 16, in which said article is a magazine, a book, a container of food, a beverage container, a wrapper or a box. 18. The method of claim 16 or 17, wherein said magnetic assembly also has a overlaminated above said substrate layer printable. 19. The method of claim 18, in which said overlaminate is substantially perforated with the same dimensions as said magnetic set. 20. The procedure of any of the claims 1 to 19, wherein said magnetic layer is continuous with said printable layer, or said magnetic layer is applied to said printable layer according to a discontinuous design. 21. The procedure of any of the claims 1 to 20, wherein said magnetic layer and said Printable layer are equivalent in length and width. 22. A procedure of forming a set magnetic according to any one of claims 1 to 21, in which adequate adhesion is obtained between said layer magnetic and said printable substrate layer without any layer of additional adhesive between said magnetic layer and said layer of printable substrate. 23. The procedure of any of the claims 1 to 22, wherein said hot melt magnetic comprises a concentration of 75% by weight to 95% by weight of said at least one magnetic material, and from 5% by weight to 25% in weight of said thermoplastic binder. 24. The procedure of any of the claims 1 to 23, wherein said hot melt magnetic comprises a concentration of 80% by weight to 92% by weight of said at least one magnetic material, and from 8% by weight to 20% in weight of said thermoplastic binder. 25. The method of claim 24, in which said magnetic hot melt comprises a concentration of 85% by weight to 90% by weight of said at least one magnetic material, and from 10% by weight to 15% by weight of said thermoplastic binder. 26. An article that is susceptible to self-adhere to a magnetic metal surface, which includes: a) a first magnetic layer of a composition hot melt magnetic, comprising the composition hot melt magnetic a concentration of 70% by weight at 95% by weight of at least one magnetic material and about 5% by weight to about 30% by weight of at least one polymer thermoplastic, and b) a second layer of a material printable; wherein said first layer and said second layer are directly adhered to each other by virtue of accession provided by the hot melt composition. 27. The article of claim 26, in the that this article is a reminder, a greeting card, a postcard, a coupon, a tag, a business card, an advertisement, a calendar, a recipe, a catalog or a promotional card 28. The article of claim 26 or 27, in which said first layer has a thickness of approximately 50 µ to about 765 µ. 29. The article of any of the claims 26 to 27, wherein said at least one composition binder comprises at least one component chosen in the group consisting of natural rubbers, block copolymers, polyolefins, polyalphaolefins, polyesters, polyamides, nails, polyurethanes, copolymers thereof, or mixtures thereof same. 30. The article of any of the claims 26 to 29, wherein said at least one binder is a amorphous polypropylene or copolymer thereof, an interpolymer of ethylene and at least one alphaolefin, a copolymer of ethylene and vinyl acetate, an ethylene copolymer and n-butyl acrylate, a copolymer of ethylene and (meth) acrylate, or a mixture thereof. 31. The article of any of the claims 26 to 30, wherein said magnetic material comprises at least one compound having the formula M 2+ O6Fe 2 O 3, in which M represents a metal divalent 32. The article of claim 31, in the that said divalent metal is barium, strontium, lead, or a mixture thereof. 33. The article of claim 26, in the that a plurality of laminated assemblies are arranged forming layers each other, to form a stacked block, and the plurality of laminated assemblies are joined together by one end. 34. The article of one of claims 26 to 33, wherein said magnetic hot melt comprises a concentration of 75% by weight to 95% by weight of said at least one magnetic material, and from 5% by weight to 25% by weight of said thermoplastic binder. 35. The article of claim 34, in the that the hot melt magnetic composition comprises a concentration of 80% by weight to 92% by weight of said at least one magnetic material, and from 8% by weight to 20% by weight of said thermoplastic binder. 36. The article of claim 35, in the that said magnetic hot melt comprises a concentration from 85% by weight to 90% by weight of said at least one material magnetic and 10% by weight to 15% by weight of said binder thermoplastic